1996 SUBARU LEGACY power steering

4. Steering Gearbox (Power Steering
System) [RHD model]
NOTE:
For disassembly and assembly of gearbox unit, refer to
section Control Valve (Power Steering Gearbox).
B4M0666A
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 20±4 (2.0±0.4, 14.5±2.9)
T2: 25±5 (2.5±0.5, 18.1±3.6)
T3: 39±10 (4.0±1.0, 29±7)
T4: 64±10 (6.5±1.0, 47±7)
T5: 78±10 (8.0±1.0, 58±7)
T6: 83±5 (8.5±0.5, 61.5±3.6)
28
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

1Dust cover

2Valve housing

3Y-packing

4Ball-bearing

5Spacer

6Pinion

7Shim

8Dust seal

9Clip

10Tie-rod end

11Clip

12Boot

13Wire

14Tie-rod RH

15Lock washer

16Sleeve
17Spring

18Adjusting screw

19Lock nut

20Pipe A

21Pipe B

22Adapter

23Housing ASSY

24Back-up washer

25Oil seal

26Rack

27O-ring

28Oil seal

29Y-packing

30Bush

31Holder

32Tie-rod LH
29
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

A: REMOVAL
1) Disconnect battery negative terminal.
2) Disconnect both oxygen sensor and exhaust gas tem-
perature warning sensor connectors from front exhaust
pipe assembly.
WARNING:
Be careful as exhaust pipe is hot.
3) Raise vehicle with a jack and remove front wheel.
4) Disconnect front exhaust pipe assembly.
G4M0097
5) Remove cotter pin and castle nut. Using a puller,
remove tie-rod end from knuckle arm.
G4M0098
6) Remove jack-up plate and stabilizer.
G4M0786
7) Disconnect one pipe joint A from center of gearbox
assembly, and connect a vinyl hose to it. While turning
steering wheel to the left and right, drain fluid through the
hose. Similarly, drain fluid from the other pipe joint B.
G4M0787
8) Remove lower and upper bolts from universal joint, and
remove universal joint in the upward direction.
NOTE:
Scribe alignment marks on universal joint so that it can be
reassembled at the original serration.
30
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

9) Remove flare nuts from control valve of gearbox
assembly, and disconnect upper and lower hoses B and A.
CAUTION:

Always disconnect hoses B and A in that order.

Be careful not to damage the hoses during removal.
10) Remove bolts securing gearbox to crossmember, and
detach gearbox.
G4M0788
B: DISASSEMBLY
1) Disconnect four pipes from gearbox.
2) Secure gearbox removed from vehicle in vice using ST.
ST 926200000 STAND
CAUTION:
Secure the gearbox assembly in a vice using the ST as
shown. Do not attempt to secure it without this ST.
G4M0789
3) Pry off clip from outer end of boot, and slide boot toward
tie-rod end.
G4M0790
4) Using ST, remove lock wire from inner end of boot, and
remove boot.
ST 927590000 WRENCH
G4M0791
5) Extend rack approximately 40 mm (1.57 in) out. Unlock
lock wire at lock washer on each side of tie-rod end using
a standard screwdriver.
CAUTION:
Be careful not to scratch rack surface as oil leaks may
result.
31
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

G4M0792
6) Using ST, loosen lock nut.
ST 926230000 SPANNER
G4M0793
7) Tighten adjusting screw until it no longer tightens.
G4M0794
8) Using a wrench [32 mm (1.26 in) width across flats] or
adjustable wrench, remove tie-rod.
CAUTION:

Check ball joint for free play, and tie-rod for bends.
Replace if necessary.

Check dust seals used with tie-rod end ball joint for
damage or deterioration. Replace if necessary.
9) Loosen adjusting screw and remove spring and sleeve.
CAUTION:
Replace spring and/or sleeve if damaged.
G4M0795
10) Disconnect pipes A and B from steering body and con-
trol valve housing.
CAUTION:
Replace pipes and/or flare nuts if damaged.
32
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

C: INSPECTION
1) Clean all disassembled parts, and check for wear,
damage, or any other faults, then repair or replace as nec-
essary.
2) When disassembling, check inside of gearbox for water.
If any water is found, carefully check boot for damage,
input shaft dust seal, adjusting screw and boot clips for
poor sealing. If faulty, replace with new parts.
No. Parts Inspection Corrective action
1 Input shaft(1) Bend of input shaft
(2) Damage on serrationIf bend or damage is excessive, replace
entire gearbox.
2 Dust seal(1) Crack or damage
(2) WearIf outer wall slips, lip is worn out or damage
is found, replace it with new one.
3 Rack and pinion Poor mating of rack with pinion(1) Adjust backlash properly.
By measuring turning torque of
gearbox and sliding resistance of rack,
check if rack and pinion engage
uniformly and smoothly with each
other.
(Refer to“Service limit”.)
(2) Keeping rack pulled out all the way so
that all teeth emerge, check teeth for
damage.
Even if abnormality is found in either
(1) or (2), replace entire gearbox.
4 Gearbox unit(1) Bend of rack shaft
(2) Bend of cylinder portion
(3) Crack or damage on cast iron portionReplace gearbox with new one.
(4) Wear or damage on rack bushIf free play of rack shaft in radial direction is
out of the specified range, replace gearbox
with new one. (Refer to“Service limit”.)
(5) Wear on input shaft bearingIf free plays of input shaft in radial and axial
directions are out of the specified ranges,
replace gearbox with new one.
(Refer to“Service limit”.)
5 Boot Crack, damage or deterioration Replace.
6 Tie-rod(1) Looseness of ball joint
(2) Bend of tie-rodReplace.
7 Tie-rod end Damage or deterioration on dust seal Replace.
8 Adjusting screw spring Deterioration Replace.
9 Boot clip Deterioration Replace.
10 Sleeve Damage Replace.
11 Pipes(1) Damage to flared surface
(2) Damage to flare nut
(3) Damage to pipe
(4) Damage to O-ringReplace.
33
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

G4M0796
G4M0797
1. SERVICE LIMIT
Make a measurement as shown in the figures. If it exceeds
the specified service limit, adjust or replace.
NOTE:
When making a measurement, vise gearbox by using ST.
Never vise gearbox by inserting aluminum plates, etc.
between vise and gearbox.
ST 926200000 STAND
Sliding resistance of rack shaft:
Service limit
304 N (31 kg, 68 lb) or less
Difference between left and right sliding resistance
Less than 20%
G4M0798
2. RACK SHAFT PLAY IN RADIAL DIRECTION
Right-turn steering:
Service limit
Less than 0.4 mm (0.016 in) (direction
)
Less than 0.6 mm (0.024 in) (direction
)
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0799
Left-turn steering:
Service limit
Less than 0.4 mm (0.016 in)
(direction
and)
On condition
L: 5 mm (0.20 in)
P: 98 N (10 kg, 22 lb)
G4M0800
3. INPUT SHAFT PLAY
In radial direction:
Service limit
0.18 mm (0.0071 in) or less
On condition
P: 98 N (10 kg, 22 lb)
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4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]

G4M0801
In axial direction:
Service limit
0.27 mm (0.0106 in) or less
On condition
P: 20—49N(2—5 kg, 4—11 lb)
G4M0802
4. TURNING RESISTANCE OF GEARBOX
Using ST, measure gearbox turning resistance.
ST 926230000 SPANNER
Service limit:
Straight-ahead position within 30 mm (1.18 in)
from rack center
Less than 11.18 N (1.14 kg, 2.51 lb)
Maximum allowable resistance
15.79 N (1.61 kg, 3.55 lb) or less
Difference between left and right sliding resistance:
Less than 20%
D: ASSEMBLY
CAUTION:
Use only SUBARU genuine grease for gearbox.
Specified grease for gearbox:
VALIANT GREASE M2 (Part No. 003608001)
1) Clean all parts and tools before reassembling.
2) Move rack shaft fully to the left and right two or three
times to lubricate shaft ends with grease. Remove excess
grease, being careful not to block air vent hole.
CAUTION:

When rack is fully moved to its stroke ends with tie-
rod removed, be careful not to bump rack ends.

Ensure that screw located at end of rack shaft is free
from grease.
3) Apply grease to bore wall which accommodates sleeve.
CAUTION:
Ensure that hands are clean when applying grease.
35
4-3SERVICE PROCEDURE
4. Steering Gearbox (Power Steering System) [RHD model]